Carrier AQUASNAP 30RB060-390 User Manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300028-01 Printed in U.S.A. Form 30RB-3T Pg 1 12-09 Replaces: 30RB-2T
Controls, Start-Up, Operation, Service
and Troubleshooting
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . .3
Basic Control Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
• SCROLLING MARQUEE DISPLAY
• ACCESSORY NAVIGATOR™ DISPLAY MODULE
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Scroll Protection Module (SPM). . . . . . . . . . . . . . . . . . . . . .7
Electronic Expansion Valve (EXV) Board . . . . . . . . . . . .8
Fan Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Reverse Rotation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
• DIAL SETTINGS
• PHASE REVERSAL PROTECTION
• PHASE LOSS AND UNDER-VOLTAGE
PROTECTION
Enable-Off-Remote Contact Switch. . . . . . . . . . . . . . . . .13
Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . .13
Energy Management Module (EMM) . . . . . . . . . . . . . . . .14
Energy Management Module
Heat Reclaim (EMM HR) . . . . . . . . . . . . . . . . . . . . . . . . . .15
Local Equipment Network . . . . . . . . . . . . . . . . . . . . . . . . . .16
Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Control Module Communication . . . . . . . . . . . . . . . . . . . .16
•RED LED
• GREEN LED
• YELLOW LED
Carrier Comfort Network
®
(CCN) Interface . . . . . . . . . .16
Configuration Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
• MINIMUM LOAD CONTROL
• RAMP LOADING
• MINUTES OFF TIME
Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
• CAPACITY CONTROL OVERRIDES
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPTION
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONS
Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Machine Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . .32
• SWITCH CONTROL
• TIME SCHEDULE
• CCN CONTROL
• UNIT RUN STATUS
Cooling Set Point Selection . . . . . . . . . . . . . . . . . . . . . . . .33
• SET POINT 1
• SET POINT 2
•4 TO 20 mA INPUT
• DUAL SWITCH
• SET POINT OCCUPANCY
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
• 2-STEP SWITCH CONTROLLED
Page
• EXTERNALLY POWERED (4 to 20 mA Controlled)
• CCN LOADSHED CONTROLLED
Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . . . . . 41
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,44
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
• TEMPERATURES
•VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-49
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dual Chiller Sequence of Operation . . . . . . . . . . . . . . . . 45
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Optional Heat Reclaim Module . . . . . . . . . . . . . . . . . . . . . 49
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-57
Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . . . . 49
• EXV TROUBLESHOOTING PROCEDURE
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
• FREEZE PROTECTION
• LOW FLUID TEMPERATURE
• LOSS OF FLUID FLOW PROTECTION
• TUBE PLUGGING
• RETUBING
• TIGHTENING COOLER HEAD BOLTS
• CHILLED WATER FLOW SWITCH
RTPF Condenser Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
• REMOVE SURFACE LOADED FIBERS
• PERIODIC CLEAN WATER RINSE
• ROUTINE CLEANING OF COIL SURFACES
MCHX Condenser Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Refrigerant Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• LEAK TESTING
• REFRIGERANT CHARGE
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• COMPRESSOR PROTECTION
• CRANKCASE HEATERS
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• HIGH-SIDE PROTECTION
• LOW-SIDE PROTECTION
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• COMPRESSOR REPLACEMENT
• OIL CHARGE
• SYSTEM BURNOUT CLEANUP PROCEDURE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Recommended Maintenance Schedule . . . . . . . . . . . . . 57
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-81
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• DIAGNOSTIC ALARM CODES AND POSSIBLE
CAUSES
AQUASNAP
®
30RB060-390
Air-Cooled Liquid Chillers

Carrier AQUASNAP 30RB060-390 Specifications

General

Brand	Carrier
Model	AQUASNAP 30RB060-390
Category	Chiller
Language	English

Summary

Controls, Start-Up, Operation, Service and Troubleshooting

SAFETY CONSIDERATIONS

Essential safety precautions before installation and servicing.

GENERAL

General information about the chiller and manual conventions.

Conventions Used in This Manual

Basic Control Usage

Describes how to navigate the scrolling marquee display and accessory navigator.

ACCESSORY NAVIGATOR™ DISPLAY MODULE

Details on the optional mobile user interface for the control system.

CONTROLS

Main Base Board (MBB)

Describes the MBB as the heart of the control system, monitoring inputs and outputs.

Scroll Protection Module (SPM)

Explains the SPM's role in controlling compressors, contactors, and heaters.

Electronic Expansion Valve (EXV) Board

Details the EXV board's function in monitoring thermistors and signaling EXV motors.

Fan Boards

Fan Board 1 (AUX1, AUX2) Outputs

Details the outputs for Fan Board 1, used with AUX1/AUX2.

Fan Board 2 (AUX1, AUX2) Outputs

Details the outputs for Fan Board 2, used with AUX1/AUX2.

Reverse Rotation Board

DIAL SETTINGS

Explains the dial settings for phase reversal and under-voltage protection.

PHASE REVERSAL PROTECTION

Describes the protection against incorrect three-phase power sequence.

PHASE LOSS AND UNDER-VOLTAGE PROTECTION

Details protection against phase loss or voltage drops.

Energy Management Module (EMM)

Energy Management Module Heat Reclaim (EMM HR)

Explains the EMM HR option for heat reclaim functionality and its inputs/outputs.

Control Module Communication

RED LED

Explains the meaning of the red status LED for proper operation.

GREEN LED

Explains the function of the green LEN status LED.

YELLOW LED

Explains the function of the yellow CCN communication LED.

Configuration Options

MINIMUM LOAD CONTROL

Reduces capacity via hot gas bypass for precise temperature control.

RAMP LOADING

Limits the rate of change of leaving fluid temperature.

MINUTES OFF TIME

Adds a time delay to the start when the machine is commanded ON.

Capacity Control

Compressor Wear Factor

Formula for calculating compressor wear based on starts and run hours.

Head Pressure Control

LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPTION

Describes the option for controlling head pressure in low ambient conditions.

LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPERATING INSTRUCTIONS

Details the operation of the low ambient head pressure control system.

Siemens VFD Head Pressure Control Parameters

DIP switch settings

Configuration settings for DIP switches on the VFD.

Siemens VFD Programming

Instructions for programming the Siemens VFD via the operator panel.

Troubleshooting the Siemens VFD with the Operating Panel

If the motor fails to start, check the following:

Lists checks for when the motor fails to start.

Cooler Pump Control

Machine Control Methods

Explains how machine operation is controlled via three variables.

Machine Control Methods

SWITCH CONTROL

Describes local machine control via the Enable/Off/Remote Contact switch.

TIME SCHEDULE

Details operation based on a programmed local schedule.

CCN Global Time Schedule

Explains using a CCN global schedule for unit operation.

Cooling Set Point Selection

Set POINT 1

Configures the unit's active set point based on Cooling Set Point 1.

Set POINT 2

Configures the unit's active set point based on Cooling Set Point 2.

4 TO 20 mA INPUT

Sets active set point based on an external 4-20 mA signal.

DUAL SWITCH

Selects active set point based on dual switch contacts.

To use Space Temperature Reset

To use 4-20 mA Temperature Reset

Configures four variables for temperature reset using a 4-20 mA signal.

Demand Limit

2-STEP SWITCH CONTROLLED

Reduces maximum capacity to user-configurable percentages via switch inputs.

EXTERNALLY POWERED (4 to 20 mA Controlled)

Reduces maximum capacity linearly based on a 4-20 mA signal input.

CCN LOADSHED CONTROLLED

Limits capacity via CCN control for demand limit.

PRE-START-UP

System Check

Checks auxiliary components, valves, and electrical connections before starting.

Operating Limitations

TEMPERATURES

Lists unit operating temperature limits.

VOLTAGE

Details acceptable supply voltages and phase imbalance limits.

MINIMUM FLUID LOOP VOLUME

Specifies required fluid loop volumes for proper temperature control.

FLOW RATE REQUIREMENTS

Sequence of Operation

Describes the step-by-step process when a chiller start command is issued.

Dual Chiller Sequence of Operation

Explains the operation sequence for two parallel chiller units.

Optional Heat Reclaim Module

Selecting the heat reclaim mode

Explains how to select heat reclaim mode locally or via CCN.

SERVICE

Electronic Expansion Valve (EXV)

Provides a cutaway view and details on the EXV's operation and function.

EXV TROUBLESHOOTING PROCEDURE

Step-by-step guide to diagnose and correct issues with the EXV.

Inspecting/Opening Electronic Expansion Valves

Installing EXV Motor

Instructions for reinstalling the EXV motor assembly.

TIGHTENING COOLER HEAD BOLTS

Gasket Preparation

Guidelines for preparing and using gaskets during reassembly.

CHILLED WATER FLOW SWITCH

Details the factory-installed flow switch and its function.

RTPF (Round Tube Plate Fin) Condenser Coil Maintenance and Cleaning Recommendations

REMOVE SURFACE LOADED FIBERS

Procedure for removing surface fibers from coils.

PERIODIC CLEAN WATER RINSE

Recommends periodic rinsing for coils in coastal or industrial environments.

ROUTINE CLEANING OF COIL SURFACES

Essential monthly cleaning procedures for coil surfaces.

Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations

Condenser Fans

Describes the fan mounting, shroud, and wire guard.

Refrigerant Circuit

LEAK TESTING

Procedures for conducting a leak test on the refrigerant circuit.

REFRIGERANT CHARGE

Instructions for charging liquid refrigerant into the circuit.

Charging with Unit Off and Evacuated

Steps for charging refrigerant when the unit is off.

Charging with Unit Running

Procedures for adding refrigerant while the unit is operating.

Safety Devices

COMPRESSOR PROTECTION

Details safety devices like circuit breakers and high-pressure switches.

CRANKCASE HEATERS

Explains the function of crankcase heaters.

SYSTEM BURNOUT CLEANUP PROCEDURE

MAINTENANCE

Provides guidelines for routine and monthly maintenance tasks.

TROUBLESHOOTING

Alarms and Alerts

Explains how the control system generates and handles warnings and fault conditions.

DIAGNOSTIC ALARM CODES AND POSSIBLE CAUSES

Motor Temperature Too High

Identifies alarms related to high compressor motor temperature.

Crankcase Heater Failure

Identifies alarms related to crankcase heater failures.

High Pressure Switch

Identifies alarms triggered by the high-pressure switch.

Process Failure

FC-n0 No factory configuration

Identifies alarms related to missing factory configuration.

FC-01 Illegal factory configuration Number #1 to nn

Identifies alarms for illegal factory configuration numbers.

MC-nn Master chiller configuration error Number #1 to nn

Identifies alarms for master chiller configuration errors.

P-01 Water Exchanger Freeze Protection

Identifies alarms related to water exchanger freeze protection.

P-05 Circuit A Low Suction Temperature

Identifies alarms for low suction temperature in Circuit A.

Compressor Not Started or Pressure Not Established

P-16 — Compressor A1 Not Started or Pressure Not Established

Identifies alarms when compressor A1 does not start or establish pressure.

Reclaim Operation Failure

P-34 — Circuit A

Identifies reclaim operation failure for Circuit A.

P-35 — Circuit B

Identifies reclaim operation failure for Circuit B.

Repeated High Discharge Gas Overrides

P-37 — Circuit A

Identifies repeated high discharge gas overrides for Circuit A.

Repeated Low Suction Temperature Overrides

P-40 – Circuit A

Identifies repeated low suction temperature overrides for Circuit A.

Water Exchanger Temperature Sensors Swapped

Pr.01 — Circuit A Discharge Transducer

Identifies alarms for failure of the discharge transducer in Circuit A.

Pr.04 — Circuit A Suction Transducer Failure

Identifies alarms for failure of the suction transducer in Circuit A.

Thermistors

COOLER LEAVING FLUID SENSOR

Describes the cooler leaving fluid sensor installation and function.

COOLER ENTERING FLUID SENSOR

Describes the cooler entering fluid sensor installation and function.

DUAL CHILLER LWT

Details the dual chiller leaving water thermistor installation.

COMPRESSOR RETURN GAS TEMPERATURE

Describes the compressor return gas temperature thermistor installation.

OUTDOOR AIR TEMPERATURE

REMOTE SPACE TEMPERATURE

Describes the remote space temperature sensor installation and wiring.

Service Test

Manual Sequence

Explains how to use the manual sequence for testing components.

QUIC (Quick Test Mode)

Details how to use the quick test mode for testing non-refrigeration items.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — RUN STATUS

Lists parameters and their values in RUN STATUS mode.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — TEMPERATURE

Lists temperature parameters and their ranges for the local display.

MODE — PRESSURE

Lists pressure parameters and their ranges for the local display.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — SET POINTS

Lists set point parameters and their default values.

MODE — INPUTS

Lists general inputs and their status for the local display.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — OUTPUTS

Lists outputs for various circuits and general functions.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — CONFIGURATION

Lists configuration parameters, their ranges, and defaults.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — TIMECLOCK

Lists timeclock settings for schedules and holidays.

APPENDIX A — LOCAL DISPLAY TABLES (cont)

MODE — OPERATING MODES

Lists available operating modes and their descriptions.

MODE — ALARMS

Lists current and historical alarms for the unit.

APPENDIX B — CCN TABLES (cont)

STATUS DISPLAY TABLES

Lists parameters available via CCN for status display.

APPENDIX B — CCN TABLES (cont)

CONFIGURATION DISPLAY TABLES

Lists configuration parameters available via CCN.

APPENDIX B — CCN TABLES (cont)

SETPOINT DISPLAY TABLES

Lists setpoint parameters available via CCN.

APPENDIX B — CCN TABLES (cont)

MAINTENANCE DISPLAY TABLES

Lists maintenance parameters available via CCN.

APPENDIX B — CCN TABLES (cont)

SERVICE DISPLAY TABLES

Lists service parameters available via CCN.

APPENDIX C — CCN ALARM DESCRIPTION

Thermistor Failure

Lists alarm codes and messages for thermistor failures.

Pressure Transducer Failure

Lists alarm codes and messages for pressure transducer failures.

Communication with Slave Board Failure

Lists alarms for loss of communication with slave boards.

APPENDIX C — CCN ALARM DESCRIPTION (cont)

Process Failure

Lists alarm codes and messages for process failures.

APPENDIX C — CCN ALARM DESCRIPTION (cont)

Service Failure

Lists alarm codes and messages for service failures.

APPENDIX C — CCN ALARM DESCRIPTION (cont)

Compressor Failure

Lists alarm codes and messages for compressor failures.

APPENDIX D — R-410A PRESSURE VS. TEMPERATURE CHART

START-UP CHECKLIST FOR 30RB LIQUID CHILLER

A. PROJECT INFORMATION

Section for project-specific job details.

B. PRELIMINARY EQUIPMENT CHECK

Contractor checks on equipment condition and installation before start-up.

C. UNIT START-UP

Procedures for initiating the unit's start-up sequence.